Buick Regal: Engine Block Assemble

1.

Install the piston oil nozzle assemblies (2), if equipped.

CAUTION: Refer to Fastener Caution.

2. Install the piston oil nozzle bolts (1) and tighten to 10 N.m (89 lb in).

3.

Lubricate the crankshaft position sensor O-ring with engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers.

CAUTION: Refer to Component Fastener Tightening Caution.

4. Install the crankshaft position sensor (2) and bolt (1) and tighten to 10 N.m (89 lb in).

5.

Install the knock sensor (1) at 6 O' clock. Install the bolt (2) and tighten to 25 N.m (18 lb ft).

6. Install the knock sensor (4) at 5 O' clock. Install the bolt (3) and tighten to 25 N.m (18 lb ft).

7.

Install the engine oil pressure sensor (1) and tighten to 35 N.m (26 lb ft).

8.

Install the engine coolant heater assembly (1), if equipped. Tighten the assembly to 50 N.m (37 lb ft).

9. If the engine coolant heater assembly is not equipped, install the engine coolant heater hole plug (2). Tighten the plug to 60 N.m (44 lb ft).

10.

Apply sealant to all plugs prior to installation. Refer to Adhesives, Fluids, Lubricants, and Sealers.

11. Install the engine oil gallery cup plug (4).

12. Install the engine oil gallery plugs (2, 3), with sealant, and tighten to 65 N.m (48 lb ft).

NOTE: Always install the baffle with the forked end pointed up. Do not force the baffle into place. Aligning the shape of the orifice and the baffle, and gently depressing the clip will allow the baffle to easily drop into place.

13. Carefully align and install the engine block coolant baffle (1).

14.

Install the engine oil gallery plug (1), with sealant, and tighten to 65 N.m (48 lb ft).

15. Install the engine oil gallery plug (2), with sealant, and tighten to 40 N.m (30 lb ft).

CRANKSHAFT AND BEARING INSTALLATION

Special Tools

• EN-8087 Cylinder Bore Checking Gauge
• EN 45059 Angle Meter

For equivalent regional tools, refer to Special Tools.

NOTE:

• Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for use.
• If crankshaft bearing failure is due to other than normal wear, investigate the cause. Inspect the crankshaft or connecting rod bearing bores.

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:

• Tighten the bedplate to specification using the EN 45059 meter.
• Measure the bearing bore for taper and out-of-round using the EN-8087 gauge (1).
• No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.

• Method A yields measurement from which the bearing clearance can be computed.
• Method B yields the bearing clearance directly. Method B does not give any indication of bearing runout.

2.

NOTE: Do not mix inserts of different nominal size in the same bearing bore.

To measure bearing clearance for the crankshaft (1) using Method A, use the following procedure:

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart.
   Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the lower crankcase and tighten the bearing cap bolts to specification.
4. Measure bearing inside diameter (ID) in several places 90 degrees apart, average measurements.
5. Subtract journal measurement from bearing ID measurement to determine clearance.
6. Determine whether clearance is within specification.
7. If out of specification, choose different inserts.
8. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
9. Measure the crankshaft main bearing inside diameter with an inside micrometer.

3.

To measure bearing clearance using Method B, use the following procedure:

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width at 90 degrees to block/lower crankcase split line.
4. Install the bearing caps.

CAUTION: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.

5. Install the bearing cap bolts to specification.

NOTE: Do not rotate the crankshaft.

6. Remove the bearing cap, leaving the gauging plastic in place. It does not matter whether the gauging plastic adheres to the journal or to the bearing cap.
7. Measure the gauging plastic at its widest point with the scale (1) printed on the gauging plastic package.
8. Remove the gauging plastic.

Crankshaft Installation

1.

NOTE: Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for use.

NOTE: If crankshaft bearing kit has a red bearing in it, install this in the front crankshaft bearing position, closest to the crankshaft balancer.

Install the upper crankshaft bearings (1) and lubricate bearing surfaces with engine oil.

2. Install the crankshaft upper thrust bearing (2) and lubricate bearing surfaces with engine oil.

3.

Install the crankshaft (1) on the journals.

LOWER CRANKCASE INSTALLATION

Special Tools

• EN 45059 Angle Meter
• EN-51380 Seal Installer

For equivalent regional tools, refer to Special Tools.

1.

NOTE: Crankshaft bearings MUST be separated, marked, or organized in a way to ensure installation to their original location and position, when suitable for use.

Install the lower bearing halves (2), without grooves, into the lower crankcase (1). Apply oil to bearing surfaces.

2.

Ensure proper use of room temperature vulcanizing (RTV) sealant. Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealant.

NOTE:

• The block assembly surface must be free of contamination prior to applying the sealer.
• Install and align the bedplate to block within 20 minutes of applying the sealer.
• The bedplate must be fastened to final torque specification within 60 minutes of applying the sealer.

3. Apply a 4.25 mm bead of sealer directly in the groove (1) of the block to bedplate mating surfaces. Refer to Adhesives, Fluids, Lubricants, and Sealers.

4.

Install the lower crankcase (4). Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.

CAUTION: This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.

5. Install the NEW M10 x 2.00 x 116 lower crankcase bolts (1) at the inner bolt locations finger tight.

6. Install the single M8 x 1.25 x 50 lower crankcase bolt (3) finger tight.

7. Install the M8 x 1.25 x 80 lower crankcase bolts (2) at the crankcase perimeter finger tight.

Fig. 11: Lower Crankcase Bolts Tightening Sequence (1 Of 2)

8.

CAUTION: Refer to Fastener Caution.

Tighten the NEW M10 x 2.00 x 116 lower crankcase bolts in sequence using the following procedure:

1. Tighten the lower crankcase bolts a first pass in sequence to 20 N.m (15 lb ft).
2. Tighten the lower crankcase bolts a final pass in sequence using the EN 45059 meter an additional 140 degrees.

Fig. 12: Lower Crankcase Bolts Tightening Sequence (2 Of 2)

9.

Tighten the lower crankcase bolts at the crankcase perimeter in sequence to 25 N.m (18 lb ft).

10.

Install the engine oil gallery plugs (1, 2). Tighten the plugs to 65 N.m (48 lb ft).

11.

Install the oil pump flow control valve (2) and bolts (1, 3). tighten the bolts to 10 N.m (89 lb in).

12.

Using EN-51380 installer (2), install the crankshaft rear oil seal (1) flush or recessed up to 0.5 mm to block.

13. Rotate the crankshaft to ensure that it moves freely and does not bind.

14. Measure and record the crankshaft endplay. Refer to Engine Mechanical Specifications.

READ NEXT: